Multi-purpose construction module

ABSTRACT

This application relates to a light-weight, multi-purpose construction module. The module may be used, for example, as a mold for settable materials such as concrete. A plurality of modules may be aligned together in different configurations for use as a temporary road or support for use on unstable terrain, such as arctic tundra or wetlands. In yet another application the module may be deployed as a storage or shelving unit. The module comprises a deck and a plurality of wall elements projecting from the deck and defining a plurality of honeycomb-like compartments. The module may be used in conjunction with a mating cover for sealingly enclosing the module compartments.

TECHNICAL FIELD

This application relates to a multi-purpose construction module.

BACKGROUND

Construction forms for containing concrete or other settable materialsare typically fabricated on-site. After the concrete is poured and set,the forms are removed. These steps are relatively time-consuming andlabor-intensive. Moreover, since the forms are not designed to be leftin place, they do not enhance the structural integrity or strength ofthe poured concrete or other material. While the use of metalreinforcing bars and ribs is known for stabilizing and strengtheningconcrete, there is a need for more light-weight and inexpensiveconstruction solutions.

Another application where pre-formed construction modules may be used isto build temporary roads or work pads. This is particularly important inregions having unstable ground support, such as arctic tundra duringseasons when the ground is not frozen. Another example of unstableground support is in wetlands such as swamps or everglades systems. Theunstable ground makes it very difficult to deploy or move heavyequipment, such as oil drilling or exploration machinery, at certaintimes of the year. This problem is conventionally addressed by layingdown a large number of wood mats on the unstable ground to distributethe machinery weight over a larger surface area. One problem with thisapproach is that protruding nails used to maintain the wood matstogether frequently puncture vehicle tires.

Interlocking mat systems made from high density polyethylene are knownin the prior art for construction of temporary roads or other supportsurfaces. However, such mats are relatively heavy and require cranes orother specialized equipment to install or remove the mats. The need hasarisen for more light-weight and economical construction modules whichmay be quickly and reliably deployed at remote locations.

SUMMARY OF INVENTION

In accordance with the invention, a construction module comprising aplanar deck and a plurality of wall elements projecting from the deck isprovided. The wall elements define a plurality of compartments, each ofsaid compartments having a closed end defined by a portion of the deckand an open end remote from the deck. In one embodiment at least some ofthe wall elements define a plurality of parallel, spaced-apartpartitions extending longitudinally on the deck. The deck may be a sheethaving a first side and a second side, wherein the wall elements projectfrom the first side in a plane generally perpendicular to the plane ofthe sheet. A plurality of ribs may project from the second side of thesheet. The module may be economically formed from cast plastic or otherlight-weight material.

In one embodiment of the invention the module may include a plurality ofconduits, such as cylindrical pipes, extending transversely through themodule at spaced-apart intervals for threading cable connectorstherethrough. The connectors may be used for quickly aligning andsecurely coupling a plurality of modules together to form a constructionassembly, such as a temporary roadway. Other means for coupling modulestogether, such as removable connecting clips and locking pins may alsobe employed.

A cover may optionally be used in conjunction with the module forenclosing the module compartments. The cover may include a plurality ofgrooves formed therein for receiving end portions of the wall elementsremote from said deck when the module and the cover are coupledtogether. Optionally, a sealing gasket may be interposed between themodule and the cover.

BRIEF DESCRIPTION OF DRAWINGS

In drawings which describe embodiments of the invention but which shouldnot be construed as restricting the spirit or scope thereof,

FIG. 1 is a top plan view of a construction module configured inaccordance with one embodiment of the applicant's invention.

FIG. 2 is a side elevational view of the module of FIG. 1.

FIG. 3 is a bottom plan view of the module of FIG. 1.

FIG. 4( a) is a bottom perspective, partially exploded view of aplurality of modules arranged together in an aligned configuration andshowing connecting clips removed from the modules.

FIG. 4( b) is a bottom perspective view of a plurality of modulesaligned together and showing the connecting clips fully inserted forcoupling the modules together.

FIG. 4( c) is an enlarged perspective view of one connecting clip ofFIGS. 4( a) and 4(b).

FIG. 5 is a top, perspective, partially exploded view of a plurality ofmodules aligned together and showing connecting cables and locking pinsfor coupling adjacent modules together.

FIG. 6( a) is an enlarged top perspective view of a plurality of modulesaligned together and showing the locking pins for coupling end portionsof the modules together.

FIG. 6( b) is an enlarged top perspective view of the modules of FIG. 6(a) showing the locking pins in their fully inserted position flush withthe top surface of the module decks.

FIG. 7( a) is an enlarged top perspective view of a plurality of modulesaligned together in an offset pattern and showing the locking pinsremoved from the modules.

FIG. 7( b) is an enlarged top perspective view of the modules of FIG. 7(a) showing the locking pins in their fully inserted position forcoupling end portions of the modules together.

FIG. 8( a) is a side elevational view of a plurality of modules alignedtogether and showing the locking pins removed from the modules.

FIG. 8( b) is a side elevational view of the embodiment of FIG. 8( a)showing the locking pins fully inserted to couple adjacent modulestogether.

FIG. 9( a) is a side elevational view of a plurality of modules alignedtogether and showing locking pins having a length greater than the pinsof FIG. 8( a) removed from the modules.

FIG. 9( b) is a side elevational view of the embodiment of FIG. 9( a)showing the locking pins fully inserted to couple adjacent modulestogether.

FIG. 10 is an exploded, isometric view of a construction assemblycomprising a module and a cover which may be coupled together tosealingly enclose the module compartments.

FIG. 11 is an enlarged, sectional view of a portion of the assembly ofFIG. 10.

DESCRIPTION

Throughout the following description, specific details are set forth inorder to provide a more thorough understanding of the invention.However, the invention may be practiced without these particulars. Inother instances, well known elements have not been shown or described indetail to avoid unnecessarily obscuring the invention. Accordingly, thespecification and drawings are to be regarded in an illustrative, ratherthan a restrictive, sense.

This application relates to a multi-purpose construction module 10. Inthe illustrated embodiment module 10 is generally rectangular in shape.As described in further detail below, a plurality of modules 10 may bealigned in a desired configuration and releasably coupled together. Eachmodule 10 includes a deck 12 and a plurality of wall elements 14projecting from deck 12. In the illustrated embodiment deck 12 is aplanar sheet having a first side 16 and a second side 18. Wall elements14 project from first side 16 in a direction generally perpendicularthereto. As shown best in FIGS. 3, 4(a) and 4(b), some of the wallelements 14 define a plurality of parallel, spaced-apart partitions 19extending longitudinally on deck 12 to provide enhanced structuralsupport, as described below. In the illustrated embodiment, wallelements 14 are arranged to define a plurality of honeycomb-likecompartments 20 each having a closed end defined by a portion of deck 12and an open end remote from deck 12. Although compartments 20 are shownas being diamond-shaped or triangular-shaped, other shapes andarrangements are possible.

In the embodiment illustrated in FIGS. 1, 5-7 and 11, a plurality ofnarrow elongated ribs 22 project a short distance from second side 18 ofdeck 12. In this embodiment ribs 22 have the same diamond-shaped patternas wall elements 14, although other rib patterns are also possible.

A plurality of conduits 24 extend transversely through module 10 atspaced intervals. In the illustrated embodiment conduits are cylindricalpipes which extend approximately mid-way between deck first side 16 andsecond side 18. As described further below, conduits 24 are provided forthreading cable connectors 26 therethrough. Cable connectors 26 are onemeans for aligning and coupling a plurality of modules 10 togetherlengthwise. Module 10 may include cut-outs 28 at intervals coincidingwith conduits 24 to enable ready access to end portions of conduits 24and cable connectors 26.

As an alternative or additional means for coupling a plurality ofmodules together lengthwise, a plurality of connecting clips 30 may beemployed as shown in FIGS. 4( a)-4(c). Each clip 30 is generallyU-shaped and includes legs 32 sized to straddle adjacent sidewalls ofmodules 10. As best shown in FIG. 4( c), opposed clip legs 32 may alsooptionally include an aperture 34 for receiving a bolt (not shown) whichcould also pass through matching holes machined in the sidewalls ofmodules 10.

Each module 10 may also include a plurality of spaced slots or cut-outs36 formed in end portions thereof. When a pair of slots 36 are aligned,a locking pin 38 may be inserted therein to couple end portions ofadjacent modules 10 together. Modules 10 may either be arranged in afully aligned configuration (FIGS. 6( a) and 6(b)) or an offsetconfiguration (FIGS. 7( a) and 7(b)) depending upon how slots 36 onadjacent modules 10 are matched. When locking pins 38 are fully insertedinto modules 10, the outermost surface of pins 38 is flush with thesecond side 18 of deck 12 (FIGS. 6( b) and 7(b)). As shown in FIGS. 8(a) and 8(b) the size of locking pins 38 may be about the same or lessthan the depth of modules 10. Alternatively, locking pins 38 may belonger than the depth of modules 10 as shown in FIGS. 9( a) and 9(b) toanchor the modules 10 in the ground when the pins 32 are fully inserted(FIG. 9( b)).

FIG. 10 illustrates an embodiment of the invention consisting of aconstruction assembly 40 comprising a module 10 and a cover 42. As shownbest in FIG. 11, cover 42 has a first side 44 and a second side 46. Aplurality of narrow slots 48 are formed on first side 44 for receivingend portions of wall elements 14. When module 10 and cover 42 arecoupled together, compartments 20 are fully enclosed. A plurality ofnarrow elongated ribs 50 may be formed on second side of cover 42 (FIG.11). Ribs 50 are similar to ribs 22 formed on second side 18 of deck 12.

As shown in FIGS. 4( a), 4(b) and 10, module 10 may also include aplurality of male projections 52 which fit into corresponding femaleapertures 54 formed in cover 42. A gasket 56 may be interposed betweenmodule 10 and cover 42 to sealingly couple the components together (FIG.10). Further, a plurality of screw fasteners 58 may be used forfastening cover 42 to module 10.

In one preferred embodiment, both module 10 and cover 42 are formed fromplastic. For example, module 10 and cover 42 may be manufactured fromplastic molds in a mass production process. Since both module 10 andcover 42 may be formed or substantially formed from cast plastic,construction assembly 40 is very light-weight in this embodiment. In oneembodiment conduits 24 and cable connectors 26 may be formed from metal.

As will be apparent to a person skilled in the art, modules 10 may bemanufactured in any desired size or shape. By way of example, modules 10may be about 3′×8′ in size and generally rectangular in shape.

Module 10 has many possible construction applications. For example,module 10 may be used separate from cover 42 as a mold for settablematerials such as concrete. In this embodiment, one or more modules 10could be deployed as shown in FIGS. 4( a) and 4(b) with the open ends ofcompartments 20 facing upward. The settable material could be introducedinto all or some of compartments 20 through the open ends thereof.Partitions 19 provide module 10 with longitudinal strength and stabilityto prevent deformation of module 10 as compartments 20 are beingprogressively filled. Depending upon the application, multiple modulesmay be aligned and coupled together as described above to formmulti-module construction assemblies. Again, the modules 10 should becoupled together sufficiently securely to prevent deformation ordistortion of the multi-module assembly as selected modules 10 or modulecompartments 20 are filled. If necessary, bolts (not shown) may be usedin conjunction with connecting clips 30. With reference to FIG. 9( b),multiple modules 10 may also be anchored in the ground or otherunderlying support surface using locking pins 38.

In another application module 10 could be filled with sand or othergranular materials to stabilize roadways and the like and preventwashout. Depending upon the specific application, module 10 could bedeployed with the with the granular material filled within the modulecompartments 20 with the open ends of compartments 20 facing eitherupwards or downwards.

In yet another application, modules 10 may be used in conjunction withcover 42 to form a light-weight construction assembly 40 suitable formaking temporary roads and the like. This embodiment of the invention isparticularly suitable for deployment on unstable ground, such as arctictundra or wetlands. Assembly 40 is deployed in the orientation shown inFIGS. 10 and 11 with cover 42 placed on the ground surface. A pluralityof assemblies 40 may be assembled lengthwise using cable connectors 26passed through conduits 24 of the respective modules 10, as discussedabove. Since assemblies 40 are lightweight and stackable, they may bequickly deployed at the construction site, even at remote locations. Thesealing connection between respective modules 10 and covers 42 preventsentry of mud and water into compartments 20 which would otherwisesubstantially increase the weight of the assemblies 40. End portions ofmodules 10 could also be aligned and coupled together as described aboveto increase the width of the temporary roadway or other support. Thusassemblies could be used as supports to distribute weight over a largesurface area while remaining stable and structurally strong in differentweather and ground conditions. In the orientation shown in FIGS. 1, 5,6(a)-7(b), 10, and 11, ribs 22 formed on deck second side 18 projectupwardly to provide traction for vehicles traveling thereover. As shownin the drawings, deck side 18 may be a continuous sheet to provide auniform support surface. Since locking pins 38 are flush with deck side18 in their fully inserted position (FIG. 6( b) and 7(b)), they will notinterfere with vehicle traffic or the like on deck 12.

As will be appreciated by a person skilled in the art, constructionmodule 10 could be used for many other purposes and applications. Forexample, in one further application may be used as a light-weightstorage container or shelving unit. In another further applicationmodule 10 could be used as part of a scaffolding system.

As will be apparent to those skilled in the art in the light of theforegoing disclosure, many alterations and modifications are possible inthe practice of this invention without departing from the spirit orscope thereof. Accordingly, the scope of the invention is to beconstrued in accordance with the substance defined by the followingclaims.

1. A construction module comprising: (a) a planar deck; and (c) aplurality of wall elements projecting from said deck, wherein said wallelements define a plurality of compartments, each of said compartmentshaving a closed end defined by a portion of said deck and an open endremote from said deck.
 2. The construction module as defined in claim 1,wherein at least some of said wall elements define a plurality ofparallel, spaced-apart partitions extending longitudinally on said deck.3. The construction module as defined in claim 2, wherein said deck is asheet having a first side and a second side, wherein said wall elementsproject from said first side in a plane generally perpendicular to theplane of said sheet.
 4. The construction module as defined in claim 3,wherein said wall elements are arranged such that at least some of saidcompartments are diamond-shaped.
 5. The construction module as definedin claim 4, further comprising a plurality of ribs projecting from saidsecond side of said sheet.
 6. The construction module as defined inclaim 3, comprising a plurality of conduits extending transverselythrough said module at spaced-intervals for threading cable connectorstherethrough.
 7. The construction module as defined in claim 6, whereinsaid conduits are arranged in parallel and extend in a transversedirection generally perpendicular to the direction of said partitions.8. The construction module as defined in claim 7, wherein said modulecomprises lateral cut-outs formed at the locations of end portions ofsaid conduits to enable access to said end portions.
 9. The constructionmodule as defined in claim 8, comprising at least one longitudinal slotformed in an end portion of said module for receiving a locking pintherein.
 10. The construction module as defined in claim 7, wherein saidconduits extend through said wall elements at a location spaced-apartfrom said deck.
 11. The construction module as defined in claim 3,wherein some of said wall partitions formed a perimeter wall surroundingsaid module and enclosing said compartments.
 12. The construction moduleas defined in claim 1, wherein said module is formed from molded or castplastic.
 13. A construction assembly comprising: (a) a constructionmodule as defined in any one of claim 1; and (b) a cover connectable tosaid module, wherein said cover comprises a plurality of grooves formedtherein for receiving end portions of said wall elements remote fromsaid deck when said module and said cover are coupled together.
 14. Theassembly as defined in claim 13, wherein cover is a sheet having a firstside and a second side, wherein said grooves are formed on a first sideof said cover.
 15. The assembly as defined in claim 14, wherein aplurality of ribs project from said second side of said cover.
 16. Theassembly as defined in claim 14, further comprising a gasket locatedbetween said perimeter wall and said cover for sealingly coupling saidmodule and said cover together.
 17. The assembly as defined in claim 16,wherein said module comprises male connectors and wherein said covercomprises female apertures for receiving said male connectors when saidmodule and said cover are coupled together.
 18. A multi-moduleconstruction panel comprising: (a) a plurality of construction modulesas defined in claim 1; and (b) at least one connector for releasablycoupling said modules together.
 19. The construction panel as defined inclaim 18, wherein each of said modules comprises a plurality of conduitsextending transversely at spaced-intervals.
 20. The construction panelas defined in claim 19, wherein said modules are arranged so that saidconduits are aligned and wherein said at least one connector comprises acable threaded through said aligned connectors.
 21. The constructionpanel as defined in claim 18, wherein said at least one connectorcomprises a clip
 22. The construction panel as defined in claim 21,wherein said clip defines a recess for receiving perimeter wall portionsof said modules.
 23. The construction panel as defined in claim 18,wherein said modules are arranged so that said slots in said endportions of modules are aligned and wherein said at least one connectorcomprises a locking pin insertable into said slots.
 24. The constructionpanel as defined in claim 23, wherein pin is generally U-shaped andcomprises to spaced-apart prongs and a connector joining one end of saidprongs together, wherein said connector is generally flush with saiddeck when said pin is fully inserted in said aligned slots.
 25. Thepanel as defined in claim 24, wherein the length of said prongs exceedsthe depth of module, wherein said prongs anchor said panel in anunderlying support surface when said pin is fully inserted into saidaligned slots.
 26. A method of constructing a temporary support surfacecomprising: (a) providing a plurality of construction assemblies asdefined in claim 13; (b) aligning said plurality of constructionassemblies in a desired configuration; and (c) releasably coupling saidplurality of construction assemblies together.
 27. The method as definedin claim 26, wherein said coupling comprising passing one or more cablesthrough said assemblies.